Irregular automatic sampling device for lime in sintering process and sampling control method

Abstract

The invention discloses an irregular automatic sampling device for lime in a sintering process and a sampling control method. The irregular automatic sampling device is used for sampling lime in a lime conveying pipeline. The device comprises a pneumatic dome valve mounted on a lime conveying pipeline and an automatic control system, wherein the automatic control system is used for controlling the opening and closing of the sampling pneumatic dome valve. An irregular automatic sampling program is written in the automatic control system, an operator needs to manually set the total sampling time and the sampling frequency according to the lime amount and the air conveying speed of the lime tank truck, the program automatically generates several random sampling time nodes according to the set time range and the sampling frequency, and irregular automatic sampling of lime is achieved. The device can reduce the labor intensity of personnel, improve the operation safety, avoid the interference of human factors on the sampling process, and ensure that the sample has higher randomness and representativeness.

Description

Technical Field

[0001] This invention belongs to the field of sintering technology, and particularly relates to an automatic sampling device and sampling control method for irregular lime in the sintering process. Background Technology

[0002] Quicklime is one of the main solvents in the sintering process. During sintering, quicklime (mainly composed of calcium oxide) can react with acidic gangue (such as silica) in the ore to form low-melting-point compounds, thereby lowering the sintering temperature and reducing energy consumption. Furthermore, quicklime can improve the strength and reducibility of sintered ore. Therefore, adding an appropriate amount of quicklime as a solvent plays a crucial role in improving the quality and yield of sintered ore. The quality of quicklime directly affects various quality indicators of sintered ore. For example, a high effective calcium oxide content in quicklime promotes the sintering reaction, improving the strength and metallurgical properties of the sintered ore; highly reactive quicklime accelerates the sintering process, resulting in more uniform and complete consolidation of the sintered ore; a suitable particle size distribution of quicklime improves the permeability of the mixture; and if the quicklime contains a large amount of impurities such as sulfur and phosphorus, it will affect the grade and quality of the sintered ore. Given the significant impact of quicklime quality, a stable and high-quality quicklime supply is key to ensuring the quality of sintered ore, and the sampling and testing process is a crucial step in ensuring quicklime quality.

[0003] Currently, common sampling methods for sintered quicklime include manual sampling, automatic sampling machine sampling, unloading port sampling, and random sampling. However, these existing sampling methods generally have the following drawbacks: manual sampling requires operators to use tools (such as shovels) to directly collect samples from the conveying pipe or unloading port, resulting in high labor intensity and susceptibility to human factors, potentially leading to inaccurate or unrepresentative sampling. While using specially designed automatic sampling machines can reduce manual operation and improve sampling accuracy and representativeness, their predictable operation allows for some human intervention, potentially leading to deliberate avoidance or targeting of the sampling pattern. Unloading port sampling allows for real-time sampling during unloading, but attention must be paid to the location and setup of the sampling device to ensure sample representativeness. Random sampling requires adherence to specific sampling rules, necessitating consideration of both randomness and representativeness. In summary, existing quicklime sampling processes generally suffer from issues related to accuracy, safety, and efficiency, and their predictable sampling patterns cannot completely eliminate human intervention, limiting the randomness and representativeness of the collected samples. Therefore, it is essential to design an automatic sampling device for the irregular lime in the sintering process that can completely eliminate human intervention and randomly select samples. Summary of the Invention

[0004] To address the problems of high labor intensity, poor safety, low sampling accuracy and representativeness in existing lime sampling methods for sintering processes, especially the susceptibility of regular sampling methods to human intervention, this invention provides an automatic sampling device and sampling control method for irregular lime sampling in sintering processes.

[0005] This invention is implemented as follows: an automatic sampling device for irregular lime sampling in a sintering process, used to sample lime from a lime conveying pipeline. The device comprises a sampling valve, an automatic control system, and an operating interface. The sampling valve is installed on the lime conveying pipeline to control the flow of lime samples. The automatic control system is electrically connected to the sampling valve to control its opening and closing. The operating interface is connected to the automatic control system to receive sampling parameters set by the operator. The automatic control system is configured with an automatic random sampling program. This program automatically generates random sampling time nodes based on the total sampling time and number of sampling times manually set by the operator, and controls the opening and closing of the sampling valve according to these time nodes to achieve automatic random sampling of lime.

[0006] In the above technical solution, preferably, the sampling valve is a pneumatic valve.

[0007] In the above technical solution, preferably, the sampling valve is a pneumatic dome valve.

[0008] In the above technical solution, preferably, the automatic control system also has the functions of sampling process monitoring and sampling data storage.

[0009] In the above technical solution, preferably, the automatic control system also has a manual / automatic switching function.

[0010] In the above technical solution, preferably, the sampling valve is installed at a distance of 2500mm to 3000mm from the ash-drying pipe interface.

[0011] This invention provides an automatic sampling device for irregular lime in the sintering process. It achieves irregular automatic sampling through a PLC-controlled pneumatic dome valve, and has the following advantages and beneficial effects: First, this invention reduces errors caused by human factors during lime sampling and avoids interference from human factors, ensuring more representative samples. Second, this device achieves randomized automatic operation of the entire lime sampling process, eliminating the need for frequent manual intervention, thus saving time and manpower, reducing labor intensity, and improving operational safety. More importantly, this invention achieves greater randomness in lime sampling, reducing the possibility of deliberate avoidance or targeting due to fixed patterns, while increasing sample diversity and comprehensiveness. This randomized automatic sampling system is program-controlled and can capture various random fluctuations in lime quality, enabling samples to more accurately reflect the overall quality of sintered lime and providing a more accurate basis for adjustments to the sintering production process.

[0012] The second objective of this invention is to provide a method for controlling irregular automatic sampling of quicklime in the sintering process. Using the aforementioned sampling device, the method is applied to sample quicklime from quicklime conveying pipelines. The method is characterized by the following steps: Parameter settings: Operators manually set the total sampling time and number of samples in the sampling process; Node generation: The automatic control system automatically generates random sampling time nodes based on the set total sampling time and number of sampling times; Automatic sampling: During the lime conveying process, the automatic control system controls the sampling valve to open for sampling according to the randomly generated sampling time nodes, and closes the sampling valve during non-sampling times; Process Reset: When the total sampling time ends, the automatic control system automatically resets.

[0013] In the above technical solution, preferably, in the parameter setting, the operator also needs to determine the total sampling time and the number of samplings based on the amount of lime in the lime tanker and the air conveying speed.

[0014] In the above technical solution, preferably, in the node generation step, the automatic control system determines the sampling timing by using a random time interval.

[0015] In the above technical solution, preferably, in the automatic sampling step, the sampling valve is a pneumatic dome valve. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the automatic sampling device for irregular lime in the sintering process of the present invention; Figure 2 This is a schematic diagram of the touch screen described in this invention. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0018] This invention provides an automatic sampling device and sampling control method for irregular lime removal in the sintering process. To further illustrate the structure of this invention, a detailed description is provided below in conjunction with the accompanying drawings: Example 1 This embodiment provides an automatic sampling device for irregular lime sampling in the sintering process, used to sample lime from the lime conveying pipeline. This device aims to solve the problems of high labor intensity, susceptibility to human factors leading to inaccurate sampling, and poor representativeness in traditional sampling methods.

[0019] Please see Figure 1 This device mainly includes: sampling valve 1, automatic control system and operation interface.

[0020] First, the installation location of the sampling valve was determined based on the orientation of the on-site air conveying duct 2, through analysis of the movement trajectory and flowability of the quicklime. The ideal sampling location is within 2500mm to 3000mm of the sintering quicklime conveying duct interface. Choosing this location ensures sampling is conducted in a representative area with stable quicklime delivery and good flowability, avoiding potential turbulence and non-uniformity at the duct interface, thus improving the representativeness of the sample.

[0021] The sampling valve is a DN50 pneumatic dome valve. Pneumatic dome valves feature rapid opening and closing, good sealing, and suitability for powder materials. They enable precise sampling, effectively preventing material leakage and blockage during sampling. Their rapid operation is a key technological foundation for precise random time-point control. Furthermore, to meet various process requirements and emergency situations in production, the device retains the original manual sampling valve on the sampling pipeline and also features a manual / automatic switching function, allowing operators to manually intervene in sampling when necessary, enhancing system redundancy and operational flexibility.

[0022] The automatic control system 3 uses a Siemens 200smart series PLC (Programmable Logic Controller). The PLC control system is electrically connected to the sampling valve and is used to control the opening and closing of the sampling valve, and whether to allow lime to flow into the sample container through the sampling pipeline for sampling.

[0023] The system is equipped with a random automatic sampling program. This program automatically generates random sampling time points based on the total sampling time and number of samples manually set by the operator through the interface. It then controls the opening and closing of the sampling valve according to these time points, achieving random automatic sampling of quicklime. This method of determining sampling timing using random time intervals eliminates selective sampling bias that may be caused by human factors, avoids the formation of fixed sampling patterns, and can more comprehensively cover quicklime from different batches and locations, making the samples more representative and thus more accurately reflecting the overall quality of the sintered quicklime. Furthermore, after the quicklime removal process is completed, the sampling control system automatically resets, eliminating the need for manual intervention and reducing manpower input, thereby improving overall work efficiency.

[0024] The operation interface is connected to the automatic control system and is used to receive sampling parameters set by the operator. The operation interface is configured using a 7-inch industrial touchscreen, such as... Figure 2 This touchscreen serves as a human-machine interface, providing functions such as setting sampling parameters, monitoring the sampling process, and storing sampling data. Through the touchscreen, operators can conveniently and quickly set parameters such as sampling frequency based on production conditions (e.g., the amount of lime in the lime tanker and the air conveying speed). Its user-friendly interface design enhances the ease and safety of operation.

[0025] Example 2 This embodiment details a control method applied to an automatic sampling device for irregular quicklime in the sintering process. The method is used to sample quicklime from the quicklime conveying pipeline. Through intelligent program control, this method aims to achieve safe and efficient quicklime sampling, and to make the sampling process more random. The method includes the following key steps: 1. Parameter Setting: Before sampling begins, operators must manually set the total sampling time and number of samples through an interface (such as a 7-inch industrial touchscreen) based on on-site production conditions and quality control requirements, including the amount of lime in the lime tanker and the pneumatic conveying speed. Accurate parameter setting is fundamental to ensuring sample representativeness, avoiding insufficient or excessive sampling, and helps optimize sampling efficiency.

[0026] 2. Node Generation: The randomized automatic sampling program in the automatic control system automatically calculates and generates random sampling time nodes based on the total sampling time and number of sampling times manually set by the operator. This step is the core technology for achieving "randomized" sampling. By randomizing the timing, it can capture various random fluctuations in lime quality, improving the diversity and comprehensiveness of the samples and providing a more accurate basis for adjusting the sintering production process.

[0027] 3. Automatic Sampling: During the lime conveying process (i.e., the lime removal process), the automatic control system (Siemens 200smart series PLC) controls the sampling valve (DN50 pneumatic dome valve) to open and collect the sample lime according to the randomly generated sampling time nodes, and then loads the sample lime into the sample container. Simultaneously, during non-sampling times, the PLC controls the sampling valve to remain closed. The entire sampling process is program-controlled, unaffected by human emotions or interests, ensuring the fairness of the sampling process and the objectivity of the data. This process achieves completely automatic operation of the sintering lime sampling process, eliminating the need for frequent manual operation, reducing the labor intensity of personnel, and freeing workers from heavy repetitive tasks.

[0028] 4. Process Reset: At the end of the total sampling time (i.e., after ash removal), the sampling control system automatically resets, eliminating the need for manual intervention and further improving system automation and safety. Simultaneously, this method also retains a manual operation mode for emergency situations, providing manual / automatic switching functionality to meet various process requirements in production.

[0029] The specific details of the random automatic sampling procedure are not limited. In this embodiment, the preferred method is: Algorithm for generating random sampling time nodes: The program is based on the total sampling time manually entered by the operator. ) and number of samplings ( The following logic is used to generate A random and irregular sampling time point ( ): 1. Determining the total time interval: Determining the sampling time range. .

[0030] 2. Reserved interval time: Taking into account the mechanical action time of the sampling valve and the sampling duration ( To prevent two sampling times from being too close together, a minimum safety time interval needs to be set. )(For example: =15~30 seconds).

[0031] 3. Valid Time Calculation: Since each sampling requires a short period of time... The total sampling duration is To ensure randomness, the program calculates an effective randomizable time (...). ), Right now .

[0032] 4. Random point generation: The program in Randomly generated within the interval Original random time points And sorted in ascending order.

[0033] 5. Increased Node Spacing (Anti-overlap Handling): To separate each random point, the program accumulates the sampling duration and safety interval into subsequent nodes to generate the final sampling time node. :

[0034] in For the first Second sampling, and .

[0035] 6. Output control: The program will... As the trigger point for control commands, the opening and closing of the sampling pneumatic dome valve are precisely controlled.

[0036] Through the above algorithm, the program can ensure that the sampling time interval is random and not fixed, thereby achieving random automatic sampling that completely eliminates human intervention and greatly improves the representativeness of the samples taken.

[0037] Single sampling duration ( The determination of ) Single sampling duration ( This refers to the duration from opening to closing of the sampling pneumatic dome valve. This time must be short enough to avoid taking too many samples at once, but at the same time to ensure that a sufficient and representative sample quantity is obtained.

[0038] The program determines or allows settings in the following ways. : 1. Setting based on material flow rate: It is an adjustable parameter that operators can manually input based on the amount of lime in the lime tanker and the air conveying speed.

[0039] 2. Typical time values: In practical applications, considering the powder properties of quicklime and the rapid response characteristics of the pneumatic dome valve, Typical values ​​are set in the range of 0.5 seconds to 2 seconds to ensure that the instantaneous material state in the pipeline is captured in a short time.

[0040] 3. Calculation basis: The determination of [the value] should follow the following principles:

[0041] Ensure the total sampling volume meets the testing requirements without affecting the main pipeline delivery.

[0042] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automatic sampling device for irregular lime in a sintering process, used to sample lime from lime conveying pipelines, characterized in that, The device includes: A sampling valve is installed on the quicklime conveying pipeline to control the outflow of quicklime samples; An automatic control system, electrically connected to the sampling valve, is used to control the opening and closing of the sampling valve; An operation interface, connected to the automatic control system, is used to receive sampling parameters set by the operator; The automatic control system is equipped with an irregular automatic sampling program. The program automatically generates random sampling time nodes based on the total sampling time and number of sampling times manually set by the operator, and controls the opening and closing of the sampling valve according to the time nodes to achieve irregular automatic sampling of quicklime.

2. The automatic sampling device for irregular lime in the sintering process according to claim 1, characterized in that, The sampling valve is a pneumatic valve.

3. The automatic sampling device for irregular lime in the sintering process according to claim 2, characterized in that, The sampling valve is a pneumatic dome valve.

4. The automatic sampling device for irregular lime in the sintering process according to claim 1, characterized in that, The automatic control system also has the functions of sampling process monitoring and sampling data storage.

5. The automatic sampling device for irregular lime in the sintering process according to claim 1, characterized in that, The automatic control system also has a manual / automatic switching function.

6. The automatic sampling device for irregular lime in the sintering process according to claim 1, characterized in that, The sampling valve is installed within a range of 2500mm to 3000mm from the ash-drying pipe interface.

7. A method for controlling irregular automatic sampling of quicklime in a sintering process, using the sampling device described in any one of claims 1-6, applied to sampling quicklime in a quicklime conveying pipeline, characterized in that... The method includes the following steps: Parameter settings: Operators manually set the total sampling time and number of samples in the sampling process; Node generation: The automatic control system automatically generates random sampling time nodes based on the set total sampling time and number of sampling times; Automatic sampling: During the lime conveying process, the automatic control system controls the sampling valve to open for sampling according to the randomly generated sampling time nodes, and closes the sampling valve during non-sampling times; Process Reset: When the total sampling time ends, the automatic control system automatically resets.

8. The irregular automatic sampling control method according to claim 7, characterized in that, In setting the parameters, the operator also needs to determine the total sampling time and number of samplings based on the amount of lime in the lime tanker and the air delivery speed.

9. The irregular automatic sampling control method according to claim 7, characterized in that, In the node generation step, the automatic control system uses random time intervals to determine the sampling timing.

10. The irregular automatic sampling control method according to claim 7, characterized in that, In the automatic sampling step, the sampling valve is a pneumatic dome valve.

Images